Method and apparatus for the manufacture of carpets



March 4, 1952 c LEMON ETAL 2588,1313

METHOD AND APPARATUS FOR THE MANUFACTURE OF CARPETS Filed Oct. 19, 1948 ratented Mar. 4, 1952 UNITED STATES PATENT OFFICE METHOD AND APPARATUS FOR THE MANUFACTURE OF CARPETS Cecil G. Lemon, Tidmarsh Grange, and Esme T. C. Brinton, land Quatt, near Bridgnorth, Eng- 10 Claims.

This invention has reference to a method of, and looms or apparatus for, manufacturing fabrics, more particularly carpets of the Axminster type, of the kind comprising a sheet-like backing which is surfaced or covered by yarn preferably in the form of successive rows of tufts. For example, the surfacing or covering may consist of successive rows of tufted or looped piles of wool or any suitable material.

The principal objects of the present invention are to enable fabrics of the above kind to be manufactured in a simple, speedy and economic manner, and to provide a new or improved loom apparatus for thus purpose. These principal objects are accomplished by the provision of a novel method and apparatus for successively incorporating successive rows of tufts in an adhesive coated sheet-like backing at a speed and degree of efficiency comparable with that at which the rows of tufts can be produced, to thus form a pile fabric which, superficially at least, has all of the characteristics of a conventional woven pile fabric.

Inaccordance with one feature of the present invention, fabric of the kind referred to is manufactured by a method which involves positioning of successive rows of tufts one side of a preformed sheet-like backing coated with an adhesive capable of being rendered effective by the action of heat and on subsequent cooling, hardening but remains flexible, by pressing each row of tufts in succession into intimate contact with the adhesive coated surface of the backing by means of a pair of relatively movable, opposed pressing members, one located on each side of the backing, and each of which extends transversely ofithe' backing and along the length of the rows of tufts thereon, which members also function as relatively movable, opposed electrodes and are energized from a source of high frequency electric current to give a dielectric heating effect.

Preferably, the method also involves the step of coating one side of the preformed backing with the adhesive as the transversely extending rows of tufts are being positioned upon and secured to theeibacking although, if desired, the backing, maybe pre-treated by coating one side thereof with the adhesive prior to entry of the backing into the loom for association with the surfacing or covering material.

In order to unite each successive transverse row of tufts to the backing, the latter with the row of tufts thereon is moved step by step between a pair of relatively movable, opposed, combined pressing and electrode members, one 10- cated on each side of said backing, and which members extend transversely of the direction of movement of the backing through the apparatus and are moved toward and away from each other to intermittently engage and disengage the backing and the successive rows of tufts to thus simultaneously heat the adhesive and to press each transverse row of tufts into position between successive steps of movement of the backing. While there are many adhesives available for use in carrying out the method of the present invention, an adhesive admirably suited for use consists of an ungelled mixture of a synthetic resin, such as polyvinyl chloride, with a plasticizer.

In the manufacture of carpets of the Axminster type, and of other fabrics wherein the surfacing or covering material consists of rows of tufts, each transverse row-of tufts is pressed on to the coated side of the backing as said row is positioned on said backing, the pressure being applied to the individual tufts mid-way between their ends so that only the central portions of the said tufts become embedded in, and are held by, the gelled or set adhesive. The spaced portions of the coatin of adhesive lying between the transverse rows of tufts will not be heated by the action of the combined pressing and electrode members and, in order to cause the adhesive in these spaced portions to gel, the entire fabric is subsequently heated throughout its body so as to gel or effectively set any adhesive which remained ungelled as the result of the tuft applying procedure.

In the manufacture of pile fabrics in accordance with the method, and by means of the apparatus, of the present invention, the combined pressing and electrode members are positioned one above the other in substantially vertical alignment and the backing and successive rows of transversely extending tufts pass between these members. Preferably, the lower of the two members is stationary and the backing is caused to move forwardly over it in successive steps, each step of movement being equal to the pitch of adjacent or successive rows of tufts secured transversely of the backing. During each interval wherein the backing is stationary, a transverse row of tufts is formed on the upper, adhesively coated face of the backing in line with the lower member. This is effected by the lowering of the upper member to heat the adhesive and to simultaneously press the transverse row of tufts into intimate contact with said adhesive.

In accordance with a further feature of the present invention, a loom or apparatus for manufacturing fabrics by the above referred to method, comprises means for intermittently feeding the adhesive coated backing through the loom or apparatus, mechanism for positioning the successive, spaced, transversely-extending rows of tufts upon the adhesive coated side of the said backing intermediate successive steps or forward movements of the latter, and means for pressing the individual rows of tufts on to the backing and for heating the adhesive coating in the locality or localities where the pressure is applied.

Preferably, the pressing and heating means consists of a pair of axially-aligned, relatively movable combined pressing and electrode members which are connected to a source of high frequency electric current and between which members the backing is fed, the said members being moved toward and away from each other to successively and intermittently press the backing and a row of tufts between the opposed ends of said members and to permit of the passage of high frequency current through the adhesive on the surface of said backing.

Preferably also, the loom or apparatus includes means for applying the adhesive coating to one side of the backing as the latter is fed forwardly. For instance, a roller may be J'ournalled in the loom or apparatus and may dip into a bath or reservoir of the adhesive, the backing being fed forwardly over the roller so that as the said backing moves forward step by step, the roller is rotated and a coating of adhesive is applied over the whole of that side of the backing which contacts the roller.

In a loom or apparatus for manufacturing carpets of the Axminster type or like fabrics wherein the covering or surfacing material consists of spaced, transversely-extending rows of tufts, mechanism is provided for positioning the tufts, one row at a time and intermediate successive forward movements of the backing, upon the coated side of said backing. Although the mechanism may be of any known kind which is capable of positioning the tufts of each row sideby-side and parallel to the direction of travel of the backing, preferably the said mechanism is of the type described and claimed in United States Letters Patent No. 2,539,180, issued under date of January 23, 1951, to Cecil Charles Brinton and entitled Gripper Mechanism for Axminster Carpet and Other Tufted-Fabric Looms.

The loom or apparatus may also incorporate an auxiliary heater, such as an oven or roller, through or over which the covered backing is passed to heat, and thereby gel or set, the adhesive between the localities or zones previously subjected to pressure and heat.

In order that the invention may be more readily understood and carried into practice, reference will now be made to the accompanying drawings, wherein:

Figure l is a side elevation which indicates, diagrammatically, those parts of a loom or apparatus for manufacturing carpets of the Axminster type, with which the present invention is concerned,

Figure .2 is an end elevation, on an enlarged scale, along the line aa of Figure 1, and indi cates a row of tufts positioned upon a coated backing between a pair of combined pressing and electrode members before the application of pressure and heat,

Figure 3 is a similar view to Figure 2 but indicates the combined pressing and electrode members in their pressure applying and heating position,

Figure 4 is another view similar to Figure 2 but indicates the tufts secured to the backing, and

Figure 5 is a section along the line bb of Figure 2.

As indicated in Figure 1, a loom or apparatus adapted to manufacture carpets of the Axminster type in accordance with the present invention, includes upper and lower combined pressing and electrode members I and 2 which are connected to a source of high frequency electric current. The upper member I is adapted to be lowered and raised in a vertical plane towards and away from the lower member 2, which member 2 is fixed with respect to the loom or apparatus and serves as a bed over which a length of prewoven backing 3 is guided by a system of cylinders 4, from a supply roll 5 to a winding drum 6.

Between the roll 5 and the members I, 2, the guiding cylinders 4 constrain one side of the backing to contact a portion of the peripheral surface of a roller 7 which dips into a bath of adhesive 8. Also, between the said members I and 2 and the winding drum 5, the backing is constrained to pass through an oven 9, or over a heated cylinder or equivalent device, whereby the product produced at the members I and 2 is heated throughout its mass before reaching the said drum 6.

A take-up roller I2 located between the members I, 2, and the oven 9, is rotated intermittently in steps of predetermined angular dimensions and is adapted, for example by the provision of a system of spikes around its periphery, to impart drive to the backing so that the latter is fed forwardly, also intermittently and in steps of predetermined length, from the roll 5, over the roller 1, between the members I and 2, to the winding drum 6, and, in passing over the said roller, has one side thereof coated uniformly with the adhesive 8.

The loom or apparatus also includes mechanism II], which, preferably, is of the kind described and claimed in the aforesaid United States Letters Patent No. 2,539,180 to Cecil Charles Brinton, for so positioning the tufts I I, one row at a time, upon the adhesive coated side of the backing and between the members I and 2, that the central portions of the individual tufts are disposed in the plane of the said members.

The mechanism I0 is timed to operate so that it positions a row of tufts upon the backing immediately following a forwards movement of the backing, and the positioning of each tuft row is followed by the lowering of the upper member I so that the central portions of the positioned row of tufts are squeezed between the two members I and 2 and are heated thereby and are therefore embedded in the adhesive coating, before a further forwards movement is imparted to the backing by the driven guide cylinder' l.

The tuft-covered backing, after passing through the oven 9, is wound upon the drum 6 in any known and convenient manner.

The adhesive 8, is of a fluid-like nature so that it is capable of being spread easily, quickly and uniformly over the backing and of penetrating rapidly into the backing and tuft materials. Further, although it possesses the property of gelling or setting but of remaining flexible when heated, it is capable of retaining its original fluid-like and ungelled condition indefinitely under normal room temperatures. Finally, it has a high electrical power factor so that it is heated and gelled rapidly by the passage therethroughof a high frequency electric current. A typical adhesive having the above-mentioned properties, is an ungelled mixture of a synthetic resin, such as polyvinyl chloride, with a plasticizer, such as tricresyl-phosphate.

The members I and 2 are connected to a source of alternating current having a frequency which is sufficiently high to effect rapid heating and setting of the adhesive when passed between said members. For examp1e, the frequency is preferably within the range of from twenty million cycles to three thousand million cycles per second.

In operating the loom or apparatus above described and indicated in the drawings, the backing material is fed forwards through a predetermined, intermittent step or stage which is equal to the pitch of the tuft rows, by an angular or part rotational movement of the take-up roller [2. Thus the backing moves relatively to the bath or reservoir containing the adhesive 8 and in so doing, causes the roller 1 to make a part rotational movement in the bath and to apply a coating of adhesive to and across the width of r the roller-contacting side of the backing. The preferred mechanism adequately disclosed in the aforesaid United States Letters Patent No. 2,539,180 to Cecil Charles Brinton, which mechanism is arranged adjacent to the members I and 2, is actuated to lay a row of tufts upon the coated side of the backing, the individual tufts in the row being located side-by-side parallel to the direction of travel of the backing and with their central portions vertically below the upper and movable combined pressing and electrode member I.

' The member I is then brought down towards the fixed member 2 and into pressure-applying contact with the central portions of all the tufts in the positioned row, and, simultaneously, the J sequently, since the pressure applied to the tufts embeds the central portions thereof wholly or partially in the coating of adhesive, and since the latter penetates rapidly into both the tufts and the backing by capilliarity, the tufts are anchored securely upon the backing. I is then raised and the cycle of operations is repeated to provide a tufted product in which the rows of tufts are spaced apart by a distance equal to one forward step of the backing.

As shown in the drawings, the upper member I tapers inwardly towards its lower tuft-contacting edge, the thickness of which edge is preferably in the region of one to three thirty-seconds of an inch so that a corresponding length of each tuft is pressed against the backing and is embedded, wholly or partially, in the adhesive.

The application of the pressure to the central ,portions of the tufts tends to cause their free ends to move away from the backing, and said applied pressure also disperses some of the ad- The member 6 of transverse grooves parallel to the tufts and with a single longitudinal groove at right angles to the said tufts and centrally of the said edge so as to minimize the dispersal of the adhesive forwardly and rearwardly of the central portions of the tufts. Also, again if desired, the face of the lower and fixed member 2 over which the backing travels, may be formed with a groove at right angles to the tufts and vertically below the moving member I, so as to enhance the tendency of the free tuft portions to move away from, and assume an inclination relatively to, the backing as the pressure is applied.

As the tufted product travels from the memhers I and 2, to the winding drum 6, it is heated throughout by the oven or equivalent heating device 9 so that any adhesive, particularly the adhesive in between the rows of tufts, which is not heated by the flow of high frequency current between said members I and 2 and through the adhesive, is gelled or set.

One or both of the members I and 2 may be built up from a plurality of spring loaded sections so that, should the squeezed central portion of any tuft in a row be knotted or be unduly thick, pressure is withheld or decreased only along a short portion of the row equal to the length of a single section. If desired, the individual sections, or individual groups of sec tions, may be electrically insulated from one another. 7

The above method of securing rows of tufts to a preformed backing has the advantages that the tufted product can be manufactured quickly and easily. Further, repairs or patching, by securing one or more tufts to the backing, may be effected easily and quickly by a pair of handactuated members corresponding to members I and 2 above described. Since a proportion of the adhesive penetrates through the backing, the possibility of the tufted product slipping on a polished wooden or other similar surface, is prevented or materially reduced.

Having described our invention, what we claim and desire to secure by Letters Patent is:

l. The method of making carpets of the AX- minster type or like pile fabrics which include a flexible, sheet-like backing with a surface layer of an adhesive capable of being rendered efiective by heat and, on subsequently cooling, hard I ening but remaining flexible; which comprises the steps of forming successive and independent rows of pile tufts; applying successive rows of said tuftsto the adhesive coated surface of said backing with each row spaced at a distance from a previously-applied row; and pressing each successive row of tufts into intimate contact with the adhesive coated surface of said backing and simultaneously heating said adhesive coated surface along the line of each row of pile tufts by high frequency dielectric heating.

2. Th"metlio"dcf making carpets of the Axminster type or like pile fabrics as defined in claim 1, wherein the successive rows of pile forming tufts are applied transversely of the backing and in spaced relation longitudinally of said backing, and wherein the simultaneous pressing an heating of the adhesive is effected along the transverse line or each row of pile tufts.

3. The method of making carpets of the Axminster type or like pile fabrics as defined in claim 1, wherein the rows of pile tufts are successively applied to said backing as transversely disposed, longitudinally spaced rows, and wherein the adhesive coated backing is advanced longitudinally step by step with respect to the line of application of said transverse rows to effect said longitudinal spacing of said rows on said backing.

4. The method of making carpets of the Axminster type or like pile fabrics as defined in claim 1, wherein the backing with the successively applied rows of pile tufts thereon is moved step by step between a pair of opposed, rela-' tively movable combined pressing and electrode members, and wherein said members are successively moved together over each successively formed row of pile tufts to press the individual rows into intimate contact with the adhesive on the backing and to simultaneously apply the high frequency dielectric heat to said rows during the interval between the step by step movement of said backing.

5. The method of making carpets of the Axminster type or like pile fabrics as defined in claim 1, wherein the surface layer of adhesive is applied to the backing as said backing is moved toward the point of application of the successive rows of pile tufts thereto.

6. The method of making carpets of the Axminster type or like pile fabrics as defined in claim 1, wherein the adhesive applied to the surface of the backing consists of an ungelled mixture of polyvinyl chlorideand a pgtstigiser.

7. The metlfdd offiakihg carpets of the Axminster type or like pile fabrics as defined in claim 1, wherein the body of the fabric made in accordance with said method is subsequently heated throughout to gel any ungelled portion of the adhesive on said backing.

8. An apparatus for making carpets of the Axminster type or like pile fabrics, comprising-apair of elongated, axially aligned, relatively movable, combined pressing and electrode members, means for feeding an adhesive coated backing between said members in successive intermittent steps, means for applying successive elongated rows of pile tufts to a surface of said adhesive coated backing, means for moving said members together over a row of said applied pile tufts during the interval between the successive steps of movement of said backing, and means for supplying high frequency electric current to said members, whereby when said members are moved together over a row of tufts said members press said tufts into intimate contact with the adhesive on said backing and simultaneously apply high frequency electric current to heat said adhesive.

9. Apparatus for making carpets of the Axminster type or like pile fabrics as defined in claim 8, which includes means for applying adhesive to said backing prior to feeding said backing between said combined pressing and electrode members. 1

10. Apparatus for making carpets of the Axminster type or like pile fabrics as defined in claim 8, which includes an auxiliary heater through which the backing with the successively applied rows of tufts thereon is passed, to gel any ungelled portion of the adhesive .on said backing particularly those portions of the ad-- hesive disposed between the successive rows of tufts.

CECIL G. LEMON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,844,838 Bufiington Feb. 9, 1932 1,902,921 Underwood Mar. 28, 1933 1,939,846 Fenton Dec. 19, 1933 2,179,037 Goldschmidt Nov. 7, 1939 2,422,525 Brown June 17, 194'! 2,432,412 Hacklander Dec. 9, 1947 2,475,019 Faris July 5, 1949 2,493,968 Hepner Jan. 10, 195i) 

